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Reviving A -99 Tdm 850


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#21 ChrisG

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Posted 03 August 2011 - 10:17 pm

QUOTE(anda3243 @ Wed 3rd Aug 2011, 05:22 PM) <{POST_SNAPBACK}>
One more thing. Does the tdm model have a oil pressure warning light? I can't find the light or the sensor. Why is that so? The 900 model has a oil level sensor in the oil tank, but, thats not the same thing.


No, which considering the amount of oil the 850's tend to use it's a bit silly.

Some have fitted their own though
http://www.carpe-tdm...showtopic=17013

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#22 MikC

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Posted 03 August 2011 - 11:00 pm

Gota sudden urge to buy some crash bungs sad.gif
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#23 anda3243

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Posted 04 August 2011 - 09:20 am

QUOTE(ChrisG @ Thu 4th Aug 2011, 12:17 AM) <{POST_SNAPBACK}>
No, which considering the amount of oil the 850's tend to use it's a bit silly.

Some have fitted their own though
http://www.carpe-tdm...showtopic=17013


Ok, thanks for the tip. I may build one someday.

QUOTE(MikC @ Thu 4th Aug 2011, 01:00 AM) <{POST_SNAPBACK}>
Gota sudden urge to buy some crash bungs sad.gif


I dont think that crash bungs would have helped in this case. I think he crashed in some kind of obsticle.
But I could glue the broken piece back.

#24 wicklamulla

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Posted 06 August 2011 - 10:43 pm

this is interesting as i tink the MKII 850 chassis is a bit more roomy than the 900's and slotting in a peachy 900 motor and running it off carbs is the way to go.

spyball alarm/immob, bluespot brake calipers and Stainless hoses, Fournales air adjustable shock with Remote Resevoir, forks raised 10mm thru yokes, racetech linear fork springs in 15 wt oil, Kappa wingrack/luggage, heated grips, Kedo handguards, dual heat controller to power heated jacket liner and or pants!!, Stebel 136DB horn, K&N air filter, colour matched Baglux tank cover (magnetic tank bag modified to fit cover), osram +50% headloight bulbs, headlight protector,"NitramSpecial" parking loight, tail light indicators all running on LED's & incorporate "Lite Buddies", MK7 Scottoiler fitted, taller screen, 2-2 stainless steel CCC's, Devil stainless down pipes. MKI Renntec engine crash bars & sump guard.
engine changed july 2007 on a dyno run it made 79.1BHP / Torque 59.9Had a brief flirtation with a 1999 MKIIa but it blew an exaust valve on the M5 so was sold on to be repaired.

I loike tay and hang sangwiches !

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#25 TonyDevil

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Posted 07 August 2011 - 11:59 am

QUOTE(wicklamulla @ Sat 6th Aug 2011, 11:43 PM) <{POST_SNAPBACK}>
this is interesting as i tink the MKII 850 chassis is a bit more roomy than the 900's and slotting in a peachy 900 motor and running it off carbs is the way to go.
Amen brother wickla wifgeni.gif

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My TDM :
Black 1991 850 MK1, 160k+ miles(ish, best guess really, gave up trying to keep count after 3rd set of clocks and 3rd engine), PilotRoad2 tyres, custom stubby exhaust system, bluespot calipers & goodridge braided hoses with dunlopads, maxton forks, Ohlins shock, kedo handguards, stainless TDM grill, Scottoiler with lubetube & dual nozzle thingy, Givi Wingrack2 with E45 & 2xE36s, renntec crash bars, Autocom with blueteeth & PMR radio, TomTom Rider2, Optimate IIIsp, Bagster tank cover, anti-dazzle coating
to fit : led spotlights, heated grips, new braided lines and rear caliper that actually has bleed nipples
Silver-ish 2003 900, 70k miles, PilotRoad3 front tyre (new@65k) & PR2 rear(new at 69k), Renthal 755 bars with KTM handguards, oxford unheated grips, power commander 3usb, scorpion titanium exhausts, standard screen with vario winglet thingy, stainless grill, oem centre stand, bagster tank cover, givi monokey topplate mounted on grabrail with V46 topbox, Givi PL pannier rails with E21s, crash bungs, mirror extender thingys, Halfords Advanced Laser Blue brillance bulbs, 21w led spotlights, touring scottoiler with leehenty dual nozzle, Autocom with blueteeth & PMR radio, TomTom Rider3 Urban, winter style anti-dazzle coating
to fit : led brake light strip, replacement heated grips

current rides : TDM850 3vd/mk1=tourer&scratcher, TRX850=weekend twisty toy, 2003 TDM900=commuter, 2005 
TDM900=unmolested.  Gone but not forgotton : XTZ750=overland touring toy, GS500e, GS125
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#26 anda3243

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Posted 14 August 2011 - 04:21 pm

QUOTE(wicklamulla @ Sun 7th Aug 2011, 12:43 AM) <{POST_SNAPBACK}>
this is interesting as i tink the MKII 850 chassis is a bit more roomy than the 900's and slotting in a peachy 900 motor and running it off carbs is the way to go.


Its hard to say. I would gues they are about the same, but I did not have a 900 chasis to compare to.

#27 anda3243

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Posted 14 August 2011 - 05:21 pm

The work continues

I took of the damaged oil pump cover. The damage was not so big, only one small crack.


The bushing that centrates the cover was shered.


Out of interest I compered it to the cover from 850 engine.


The 5PS cover with the 4XT(?) gasket on it on left. The 4XT cover on the right. They fit between the motors.

I fixed the 5PS cover with chemical metal. I did the fix on the pustside so if the metal comes loose it will not end up inside the engine.




Next the water pump. It was to damaged to be rapaired.
The impeler was grinding against the housing.


And the housing was bent and cracked. Difficult to se the crack on the picture tho. Note the old cylinder head in the trash tongue.gif


A quick comparision to the 4TX engine, plausible


The 5PS water pump on the left, the 4TX on the right. The bolts that goes to the engine block are identical. One ore two of the bolts holds the water pump housing and cover together. These bolts are moved a little.
The shaft that goes in to the engine is identical. The gaskets are identical. The casting is different on the different models.
The 4TX water pump will fit on a 5PS and viceversa. Sorry for the bad pics, grease on the camera lens.


Great sucess, i wont need to buy a new water pump, rebuild the old one with gaskets from the newer one. And add some grease for the bearing inside the motor. It could take some time for oil to reach this spot on startup.


Here is the damage on the engine. The piece thet has broken of contains threads for one of the water pump bults.


Fitting the new/old water pump


The damaged part of the engine was glued with chemical metal and hold in place by the water pump. It sits on the bolt thats missing in the picture. Not optimal but i think it will hold. I do not have pictures of this, will try to take a photo and post later.

With this the damaged motor was usable.

Next post, fitting the engine in the frame.


#28 3vd

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Posted 14 August 2011 - 05:30 pm

Excellent project. Keep up the good work wink.gif



#29 Studley Ramrod

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Posted 14 August 2011 - 05:55 pm


Great stuff ! Thanks for posting up the info & photos ! good.gif


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#30 wicklamulla

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Posted 15 August 2011 - 05:41 am

ohhh i'm enjoying this project !

spyball alarm/immob, bluespot brake calipers and Stainless hoses, Fournales air adjustable shock with Remote Resevoir, forks raised 10mm thru yokes, racetech linear fork springs in 15 wt oil, Kappa wingrack/luggage, heated grips, Kedo handguards, dual heat controller to power heated jacket liner and or pants!!, Stebel 136DB horn, K&N air filter, colour matched Baglux tank cover (magnetic tank bag modified to fit cover), osram +50% headloight bulbs, headlight protector,"NitramSpecial" parking loight, tail light indicators all running on LED's & incorporate "Lite Buddies", MK7 Scottoiler fitted, taller screen, 2-2 stainless steel CCC's, Devil stainless down pipes. MKI Renntec engine crash bars & sump guard.
engine changed july 2007 on a dyno run it made 79.1BHP / Torque 59.9Had a brief flirtation with a 1999 MKIIa but it blew an exaust valve on the M5 so was sold on to be repaired.

I loike tay and hang sangwiches !

www.kenhogantreeservices.co.uk

http://s33.photobuck...77/wickla/?sc=6



http://reg.imageshack.us/v_images.php

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#31 TDMick

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Posted 15 August 2011 - 05:26 pm

Me to good.gif

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#32 anda3243

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Posted 16 August 2011 - 07:18 pm

It is nice to hear that people are enjoying this. smile.gif I will write more as soon i have more pictures uploaded. There will be more comparing engine parts posts.

I have a questione in the meantime. Can you help me recognise this windscreen? I am quite sure it is not the original one, it is a bit higher I think.
I find this windscreen useless. At about 80 km/h it starts to flex and vibrate, push around the helmet and vibrate the visor if its open. Very anoying. It is better about 100 km/h and again worse at 120+ km/h. I have read a little on this forum, and this seems to be a common problem.

I have been thinking about buying a MRA vario touring screen, but are unsure. Do these screens flex and vibrate at some speeds? The variable peace should add some wieght far out on the screen, which should make it more likely to vibrate.





#33 3vd

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Posted 16 August 2011 - 08:54 pm

That looks like a yamaha touring screen, I've got an MRA Vario screen on my 9er. The vario screen is really good, I've tried a tall touring screen and much prefer the Vario. smile.gif

#34 wicklamulla

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Posted 16 August 2011 - 09:48 pm

It's a Givi touring screen, identical to mine.

spyball alarm/immob, bluespot brake calipers and Stainless hoses, Fournales air adjustable shock with Remote Resevoir, forks raised 10mm thru yokes, racetech linear fork springs in 15 wt oil, Kappa wingrack/luggage, heated grips, Kedo handguards, dual heat controller to power heated jacket liner and or pants!!, Stebel 136DB horn, K&N air filter, colour matched Baglux tank cover (magnetic tank bag modified to fit cover), osram +50% headloight bulbs, headlight protector,"NitramSpecial" parking loight, tail light indicators all running on LED's & incorporate "Lite Buddies", MK7 Scottoiler fitted, taller screen, 2-2 stainless steel CCC's, Devil stainless down pipes. MKI Renntec engine crash bars & sump guard.
engine changed july 2007 on a dyno run it made 79.1BHP / Torque 59.9Had a brief flirtation with a 1999 MKIIa but it blew an exaust valve on the M5 so was sold on to be repaired.

I loike tay and hang sangwiches !

www.kenhogantreeservices.co.uk

http://s33.photobuck...77/wickla/?sc=6



http://reg.imageshack.us/v_images.php

post-1-1150550733.gifpost-1-1150550726.gifpost-1-1150559830.gif


#35 anda3243

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Posted 17 August 2011 - 08:03 am

QUOTE(maximuspetrolhead @ Tue 16th Aug 2011, 10:54 PM) <{POST_SNAPBACK}>
That looks like a yamaha touring screen, I've got an MRA Vario screen on my 9er. The vario screen is really good, I've tried a tall touring screen and much prefer the Vario. smile.gif


Ok. How thick is the MRA Vario screen? The screen I have is quite thin about 2 to 3 mm. A thicker screen should be better

QUOTE(wicklamulla @ Tue 16th Aug 2011, 11:48 PM) <{POST_SNAPBACK}>
It's a Givi touring screen, identical to mine.


Are you sure it's givi? It has a Yamaha logo on it.


Thanks

#36 3vd

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Posted 17 August 2011 - 12:07 pm

Yeah the Vario screen is really good quality, doesn't bend about at all (not that I've ever noticed anyway).

#37 wicklamulla

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Posted 17 August 2011 - 10:57 pm

QUOTE(anda3243 @ Wed 17th Aug 2011, 09:03 AM) <{POST_SNAPBACK}>
Ok. How thick is the MRA Vario screen? The screen I have is quite thin about 2 to 3 mm. A thicker screen should be better
Are you sure it's givi? It has a Yamaha logo on it.
Thanks



so does mine and i bought it new in Givi packaging.

spyball alarm/immob, bluespot brake calipers and Stainless hoses, Fournales air adjustable shock with Remote Resevoir, forks raised 10mm thru yokes, racetech linear fork springs in 15 wt oil, Kappa wingrack/luggage, heated grips, Kedo handguards, dual heat controller to power heated jacket liner and or pants!!, Stebel 136DB horn, K&N air filter, colour matched Baglux tank cover (magnetic tank bag modified to fit cover), osram +50% headloight bulbs, headlight protector,"NitramSpecial" parking loight, tail light indicators all running on LED's & incorporate "Lite Buddies", MK7 Scottoiler fitted, taller screen, 2-2 stainless steel CCC's, Devil stainless down pipes. MKI Renntec engine crash bars & sump guard.
engine changed july 2007 on a dyno run it made 79.1BHP / Torque 59.9Had a brief flirtation with a 1999 MKIIa but it blew an exaust valve on the M5 so was sold on to be repaired.

I loike tay and hang sangwiches !

www.kenhogantreeservices.co.uk

http://s33.photobuck...77/wickla/?sc=6



http://reg.imageshack.us/v_images.php

post-1-1150550733.gifpost-1-1150550726.gifpost-1-1150559830.gif


#38 wicklamulla

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Posted 30 August 2011 - 12:02 pm

so come on then any news ferrous ??? i have logged in from Germany especially to read this FFS !!!

spyball alarm/immob, bluespot brake calipers and Stainless hoses, Fournales air adjustable shock with Remote Resevoir, forks raised 10mm thru yokes, racetech linear fork springs in 15 wt oil, Kappa wingrack/luggage, heated grips, Kedo handguards, dual heat controller to power heated jacket liner and or pants!!, Stebel 136DB horn, K&N air filter, colour matched Baglux tank cover (magnetic tank bag modified to fit cover), osram +50% headloight bulbs, headlight protector,"NitramSpecial" parking loight, tail light indicators all running on LED's & incorporate "Lite Buddies", MK7 Scottoiler fitted, taller screen, 2-2 stainless steel CCC's, Devil stainless down pipes. MKI Renntec engine crash bars & sump guard.
engine changed july 2007 on a dyno run it made 79.1BHP / Torque 59.9Had a brief flirtation with a 1999 MKIIa but it blew an exaust valve on the M5 so was sold on to be repaired.

I loike tay and hang sangwiches !

www.kenhogantreeservices.co.uk

http://s33.photobuck...77/wickla/?sc=6



http://reg.imageshack.us/v_images.php

post-1-1150550733.gifpost-1-1150550726.gifpost-1-1150559830.gif


#39 dapleb

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Posted 17 September 2011 - 04:19 am

I did wonder when you have engine mounts to fabricate, wiring, ECM and fuelling decisions to make and start worrying about the screen options. laugh.gif

Hope the project is still going. The 900 injun in mkI has been done before so there should be noubt stopping it from going in a mkII.
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#40 wicklamulla

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Posted 19 September 2011 - 09:11 pm

sling it in and run it on the MKIIa carbs i say ! be interesting to see if it'll have to run the TDM900 CDI or will he be lucky and it'll run off the MKIIa CDI ? !

spyball alarm/immob, bluespot brake calipers and Stainless hoses, Fournales air adjustable shock with Remote Resevoir, forks raised 10mm thru yokes, racetech linear fork springs in 15 wt oil, Kappa wingrack/luggage, heated grips, Kedo handguards, dual heat controller to power heated jacket liner and or pants!!, Stebel 136DB horn, K&N air filter, colour matched Baglux tank cover (magnetic tank bag modified to fit cover), osram +50% headloight bulbs, headlight protector,"NitramSpecial" parking loight, tail light indicators all running on LED's & incorporate "Lite Buddies", MK7 Scottoiler fitted, taller screen, 2-2 stainless steel CCC's, Devil stainless down pipes. MKI Renntec engine crash bars & sump guard.
engine changed july 2007 on a dyno run it made 79.1BHP / Torque 59.9Had a brief flirtation with a 1999 MKIIa but it blew an exaust valve on the M5 so was sold on to be repaired.

I loike tay and hang sangwiches !

www.kenhogantreeservices.co.uk

http://s33.photobuck...77/wickla/?sc=6



http://reg.imageshack.us/v_images.php

post-1-1150550733.gifpost-1-1150550726.gifpost-1-1150559830.gif



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